Manufacturing Group Leader

Primary Job Function:

Responsible for assigned manufacturing and reporting tasks which includes supporting and directing assigned team members and team leaders as they operate equipment or tools to weld, swage, stamp, and/or assemble parts according to customer specifications, following standard work instructions, and/or conveying parts between processes. Responsible to support team members and team leaders through safety, quality, and process concerns, including product disposition, implementation of sorting as needed, and documentation verification and approval. Responsible to perform tasks of team leaders due to absences or production fluctuations when needed. Overall responsibility for safety, quality of work, production and material flow of assigned team leaders and team members.

Primary Responsibilities/Essential Functions:

• Function as a first-line supervisor over team leaders and team members.
• Plan and coordinate hiring and placement of team members with Assistant Manager. Monitor and track staffing conditions, work hours and overtime, job rotation, and absenteeism.
• Understand, execute, and ensure consistent compliance with all company rules, policies, and practices, and take appropriate corrective action when warranted, in accordance with the terms of the Team Member Handbook.
• Manage and appraise team member job performance and recommend corrective action.
• Develop and maintain positive team member relations centered on mutual trust, dignity, respect, fairness, consistency, two-way communication, teamwork, and harmony.
• Provide direction and motivation to team members emphasizing safety, quality, efficiency, productivity, cost reduction, and morale.
• Lead and maintain the manufacturing and production system of assigned area, accomplish department hoshin goals, and keep on task with targets and implementation schedule.
• Develop standardized work procedures by designing and/or documenting the best work sequence for each process.
• Direct the work of Team Leaders and Team Members by assigning/re-assigning work stations and analyze production requirements based on current work situation and production schedules.
• Direct floor activities through consistent application of Toyota Boshoku Business Practices (TBBP) to ensure all aspects of manufacturing are effective and correct sub-standard situations.
• Perform the essential job functions of team leaders or team members as necessary to maintain efficient, stable, and continuous operations.
• Conduct time studies and other analyses on welding locations throughout the department to identify performance gaps and develop countermeasures for continuous improvement.
• Lead Team Leaders and Team Members in program launches by building familiarity with program equipment, writing work instructions, participation in program launch meetings, training other Team Members on operation of program equipment, and constructing support equipment (racks, shoots, grease machines, etc.).
• Monitor the flow of parts, materials, productivity, and quality including kanbans and inventory levels; take corrective action as needed.
• Ensure quality goals and standards are met and know how to use the quality feedback loops and systems and escalation procedures.
• Confirm that team members use the quality systems correctly.
• Partner with the Quality department to initiate investigation and containment activities.
• Troubleshoot daily quality, safety, and production issues.
• Identify potential and current change points and make the required adjustments need to ensure quality, safety, operational availability, production efficiency (PEFF), and cost control are maintained.
• Be proactive in predicting abnormalities and finding innovative solutions to correct.
• Evaluate and analyze problems involving machinery and equipment and coordinate repair of tools and machinery.
• Participate in frequent evaluation of machines, tools, equipment, etc.
• Educate employees on the importance of passing good quality parts, by means of effective paint marking, startup checks, consistent tip/nozzle cleaning, pokayokes, Stop, Call, Wait, etc.
• Lead continuous improvement activity for assigned area.
• Participate in the setting of Key Performance Indicator (KPI) targets including safety, quality, operational availability, PEFF, scrap, etc. as a method of continuous improvement.
• Maintain, monitor, and update department and KPI board and graphs, daily, and initiate continuous improvement activities.
• Initiate, coordinate, and participate in safety, quality, productivity, and cost improvement projects.
• Lead the implementation of team members' ideas and suggestions and management directed initiatives.
• Maintain a safe working environment for all team members.
• Ensure compliance with safety regulations, Personal Protective Equipment (PPE) requirements, and company safety policies and procedures.
• Lead, perform, and/or participate in ergonomic exercises, 4S housekeeping, accident investigation, and safety audits and related activities.
• Lead ergonomic assessments of team member work stations and implement countermeasures and job rotation to improve long-term safe working conditions and team member well-being.
• Maintain knowledge of procedures concerning Hazardous Waste, Spill Response, and Plant Security.
• Monitor safety and health of team members to ensure their well-being.
• Train and coach team members to maintain productivity and quality standards, in TS19649, ISO 14001, environmental, safety, quality, job performance, setups, trouble shooting, and continuous improvement.
• Orientate and oversee all training of team members and assign experienced and/or certified trainers to perform new team member training and cross training as needed.
• Maintain training matrix for team leaders and/or team members, assuring training is effective and corrects sub-standard performance.
• Maintain, plan, and prepare department instruction manuals.
• Ensure further development of team members through performance evaluation, development of training plans, feedback, coaching, and cascade training.
• Collect, record, and analyze information while maintaining documentation regarding the activities in the assigned area as defined by company policy, procedure, or practice.
• Prepare business reports and spread sheets of required data.
• Maintain specified records, files and logs of department/shift activities such as production, production problems, parts shortages, scrap, quality, maintenance, etc. (manual and computer) as required. Perform other various administrative duties.
• Monitor and maintain team member time, attendance, and training records.
• Through daily start of shift and communication meetings, keep team members informed on issues relevant to them and encourage two-way communication.
• Maintain daily and/or frequent communication with upstream and downstream groups/areas and support departments to ensure efficient and stable operations in a team-based environment.
• Coordinate communications between shifts for assigned area(s).
• Follow and understand, and support assigned team members to follow, all standard work procedures associated with each task and all company policies, as trained according to the training plan.
• Stop, call, & wait for all abnormal conditions according to TBA protocol, and respond to assigned team members to support any Stop, call, wait from them.
• Follow all safety procedures and communicate issues with AM/Manager.Utilize TPS (Toyota Production System) techniques, as trained according to the training plan, to standardize process/methods, identify waste, methodically eliminate waste and standardize the new process/methods, and train, communicate, and support assigned team members regarding the same.
• Understand and follow the TB Way philosophy, as trained according to the training plan, and adhere to the philosophy within a team-oriented environment, and train, communicate, and support assigned team members regarding the same.
• Ensure overtime coverage, when required, is communicated timely and that team members understand their assignments. Assist AM to ensure overtime needs are covered and associated policy is consistently applied.
• Work beyond the regular schedule, which could include daily and weekend overtime, as required to meet the Just-In-Time demands of the plant.
• Follow safety, quality, confidentiality, and information security policies and procedures.
• Other duties as assigned.

Minimum Qualifications/Requirements :

Education:

• Associate's degree in Business, Manufacturing, Engineering, or related field required, or an equivalent combination of education and experience. Bachelor's degree preferred.

Experience:

• Three to five years experience in manufacturing.
• Two years previous leadership or supervisory experience.
• Automotive industry experience preferred with parts production, quality, or production control experience a plus.
• Experience in automotive interiors including carpets, filters, powertrain, seating, and/or trim preferred.
• Working knowledge and experience with TPS and Production Efficiency (PEFF) system preferred.

Personal/Technical Skills:

• Demonstrated knowledge, skills, and abilities to perform the job functions of a leadership role.
• Thorough understanding of company product, trade terminology, quality management and control systems and techniques, manufacturing processes including material controls, work flow, scheduling, kanban, machine operation, and company policies as standards.
• Good mechanical aptitude.
• Active listener with effective leadership, communication, and interpersonal skills.
• Must be able to multi-task, handle diversity, and provide leadership through problem resolution.
• Good math and communication skills.
• Ability to adapt available skills and equipment to respond to unforeseen demands and/or problems.
• Ability to implement plans to control and maintain safety, quality, 4S, cost, and efficiency for assigned areas.
• Strong organization, time management, and planning skills and ability to manage multiple tasks with tight deadlines.
• Ability to teach team leaders and team members in basic fundamental skills and facilitate Job Instruction Training (JIT).
• Experience with precision measuring equipment.
• Must be able to work a fixed or rotating shift schedule, including daily or weekend overtime.
• Strong attention to detail.
• Strong customer service orientation.
• Ability to consistently show and maintain professionalism.
• Highly motivated, ambitious self-starter.
• Ability to work in a fast-paced, multicultural work environment.
• Ability to communicate and work well with all levels of the organization, and with multiple departments.
• Ability to complete forms and reports, including the ability to read, write, and follow detailed instructions.
• Ability to exercise on daily basis.
• Ability to use diverse hand tools and equipment.
• Ability to maintain on call flexibility to control abnormal conditions.
• Perceptive person, who is capable of relating to individuals at all levels.
• Ability to be adaptable and flexible in a constantly changing environment.
• Be able to maintain the confidentiality of any information encountered.

Computer/Software:

• Previous experience working with integrated computer programs and/or applications. ERP System experience (e.g., Oracle) preferred.
• Solid working knowledge and demonstrated experience with Microsoft Office and other computer-based applications (e.g., MS Word, MS Excel, MS PowerPoint, Lotus Notes/Outlook, Internet, etc.).
• Basic Microsoft Office skills preferred.

Work Environment/Conditions :

Plant:

• Standard automotive plant environment with high decibel noise levels, flashing lights, and alarms/notification systems. PPE (Personal Protective Equipment) such as safety glasses, safety toe shoes, hearing protection, etc. may be required in engineering, manufacturing, or industrial areas. Personal attire standards may apply.
• TBTN- temperature controlled environment
• Team Members are exposed to sharp metal objects that are heated during welding process. As such, Team Members are required to wear heat protective gloves and sleeves that are made from an XKS nylon material. The PPE is designed to cover all of arms and hands and can become hot during summer months.

Physical Demands:

• Capable of standing 100% of time and must be able bend, walk, & to lift up to 30 pounds. While performing the duties of this job, the team member is frequently required to grip tools and objects, stretch and/or reach with hands and arms; using hands and fingers to handle, feel, twist, walk, twisting (standing), bend at the waist, and do repetitive motions. The team member must occasionally kneel, work from heights and crouch. The team member must frequently lift and/or move five to fifteen pounds. The team member must regularly lift twenty to thirty pounds and occasionally lift and/or move over thirty pounds with the assistance of a cart, pallet jack, other mechanical device or another team member. While performing the duties of this job, the team member is required to talk, see, and hear.